Mining and metal industry solutions and products

Mining and metal industry solutions are the cornerstone of modern engineering and construction, integral to everything from skyscrapers and automobiles to infrastructure and machinery. As global demand has surged over the past five decades, the industry faces pressing challenges. Primary metals production is a significant contributor to greenhouse gas emissions. Generating more than three times the emissions of the aviation industry, the steel industry produces an average of 1.8 tons of carbon dioxide for every ton of steel produced. Embracing sustainable practices and innovative technologies is essential to meet rising demands while minimizing our environmental impact.

The industry is undergoing the current challenges of increasing demand, strong market competition, changing regulations and changing value chains. This addresses fuel, heat and power supplies and requires integrated electrical solutions to balance any type of plant. Given the nature of metal processes and the complexity and fragmentation of their value chain, there is no simple or single solution to decarbonize the industry. We understand the challenging requirements of the metal industry and our diverse portfolio of technologies supports the further growth of this heads-on.

Together, let’s shape a decarbonized future, where we not only meet today’s production demands but also significantly reduce our carbon footprint. By leveraging innovative technologies, we can pave the way for a more sustainable and interconnected metal industry.

Our portfolio includes a range of smart technologies to support the transformation journey and to shape your ideas into sound solutions. From industrial electrification to energy efficiency, waste heat recovery and fuel shift: These solutions provide a stable grid connection, ensuring a reliable and uninterrupted power supply for the efficient operation of plants.

We offer a comprehensive portfolio of solutions to serve the metal industry along the entire energy value chain:

Simplified infographic showing Siemens Energy portfolio solutions for power generation and transmission at metal industry (Steel, Aluminium, Copper etc.)

Discover the forefront of innovation and sustainability with our Metal Industry Portfolio. Our comprehensive system offerings and successful integrations are designed to meet the evolving needs of the industry. We prioritize assessing environmental impact to ensure our solutions contribute positively to the planet.

Our systems are engineered to seamlessly connect to the power grid, providing unmatched stability and enabling energy efficiency across operations. We offer cutting-edge solutions for waste heat recovery, turning potential waste into valuable resources. Additionally, we support the industry's fuel shift, paving the way for a greener future.

As the steel production industry continues to expand and new assets are added, the demand for power inevitably increases. To reduce energy costs, enhance competitiveness and comply with regulatory requirements, implementing end-to-end energy management is crucial. This approach combines conventional power systems with renewable energy sources, such as wind and solar, seamlessly integrating them into existing facilities. We offer comprehensive support in designing and integrating all power sources into a unified system, enabling customers to produce and consume power under optimal conditions. Our solutions ensure holistic optimization, reducing dependence on traditional energy sources and lowering your carbon footprint.

Check out our power transmission technologies:

Expert grid consulting services to optimize performance
High-voltage substations for reliable power transmission
STATCOM technology for voltage regulation and reactive power compensation
Reliable transformers for evolving energy sector demands
Gas-insulated switchgear with zero harmful emissions
Qstor™ battery energy storage systems for efficient energy storage
High-quality surge arresters for overvoltage protection
Cost-effective voltage regulators to stabilize grid performance

SVC PLUS® (STATCOM) for better industrial load compensation

Large electrical consumers in industrial processes often show a very dynamic behavior. Looking at the most extreme case of electrical loads worldwide, Electrical Arc Furnaces (EAFs) – where a single unit can have a consumption of up to around 300 MVA (the consumption of a city of 300.000 inhabitants) – their load characteristic is extremely dynamic and stochastic, creating a number of disturbances to the feeding grid, such as fast voltage fluctuations causing the phenomenon of flickering of light, bad power factor and asymmetric loading of the 3 phases of the supply system, as well generation of harmonics due to the non linear current of the electric arc. To counteract the disturbances of such industrial loads, an innovative and versatile compensation solution for enhancing power quality is required - SVC PLUS® provides the ideal solution. Our advanced STATCOM (static synchronous compensator) with modular multilevel converter (MMC) technology provides additional benefits compared to conventional solutions for load compensation. While conventional SVC installations already provide a highly dynamic solution for power quality improvement at the the grid connection point of an industrial power distribution system, the modular multilevel system SVC PLUS® is even faster and offers multiple additional benefits. Depending on the size and characteristics of the load and the utility regulations, we offer different SVC PLUS® concepts to mitigate the unwanted impact of the load to the grid.

Coming soon: ActiFeed PLUS

Given the dynamic load behaviors of EAFs, which can consume up to 300 MVA, Siemens Energy's SVC PLUS® STATCOM technology offers different solutions to perfectly fit your needs.

Discover the future of energy supply with ActiFeed PLUS, our innovative solution to feed three-phase electric arc furnaces maximizing energy efficiency while minimizing operating costs and environmental impact. Utilizing PLUS® technology in an advanced Modular Multilevel Matrix Converter (M3C), ActiFeed PLUS ensures precise power control for stable arcs and optimal energy utilization, resulting in reduced power-on times and unprecedented grid stability.

SVC PLUS® complements this by providing a cutting-edge STATCOM solution that enhances power quality. Each of these technologies enables modern steel plants to boost productivity, lower costs, and seamlessly meet stringent grid requirements while ensuring stability and reliability in power systems.

Integrally geared compressors and single-stage radial compressors are essential in the steel industry, particularly in blast furnace (BF) processes. These compressors supply fresh air and facilitate oxygen delivery from air separation units (ASUs) to the basic oxygen furnace (BOF), helping to reduce carbon content in pig iron. In the direct reduced iron (DRI) production, compressors manage critical gas streams, including hydrogen and carbon monoxide, under challenging conditions. Our offerings support carbon capture, utilization, and storage (CCUS) by compressing captured CO₂ for storage or utilization, ensuring efficient and sustainable operations in steel manufacturing. We provide advanced hydrogen or CO₂ compressor solutions tailored to these specific needs, ensuring efficient and reliable operation in DRI plants.

Read more in the energy industry times here.

A considerable portion of the energy consumed in the steel industry is rejected as waste heat from the electric arc furnace (EAF). Utilizing this heat impacts the efficiency of production significantly by reducing operating costs, feeding extra electricity to the grid or increasing the plant's productivity. It also presents great opportunities to increase the industry’s competitiveness and sustainable operation through a reduction in emissions.

WHRS includes a reduction in the carbon footprint of steel plant operations, lower production and operating costs, and supports organizations ESG goals to support Scope 2. Our technology uses residual heat from the exhaust gases generated in steel manufacturing process and has potential to generate electricity. Electric power expenses can account for up to 40% of total operating cost of EAF plant.

CO₂ capturing today is often done by a post-combustion amine-based carbon capture system. A typical challenge is that compressors are required for achieving maximum efficiency, which means the temperature level and the heat generation are intended to be kept as low as possible. On the other hand, an amine process requires high amounts of LP steam.

Benefits of heat integration for high process steam recovery:

Hydrogen production is crucial for turning traditional steelmaking processes to sustainable green steelmaking. Electrolyzers play a key role by providing green hydrogen using green electricity from renewable sources. This hydrogen is then compressed using compressors to increase its energy density, making it suitable for storage and transportation. The compressed hydrogen can be used in direct reduction processes to convert iron ore into steel, significantly reducing carbon emissions compared to traditional methods. This integration of electrolyzers and compressors in hydrogen production supports the metal industry's shift towards more sustainable practices.

Siemens Energy to supply reciprocating compressors for steam methane reformer

Combining our portfolio in the mining industry, Siemens Energy can support miners in their transformation journey. But we cannot do it alone, we need to work together with key players to develop sustainable energy transition solutions that allow us to design the mine of the future. Our mining industry solutions adress crushing, milling and concentration and supporting refining and smelting. This is adressed via decarbonizing the metals value chain. We are helping to shape your ideas into sound solutions. Let's talk about:

Efficiency increase
Hybrid power generation
Green fuel
Storage and power grids
Integrated mining

To thrive in the metal and mining industry, organizations need more than just reliable energy sources; they require a comprehensive approach to energy management and sustainability. Discover our a suite of services designed to enhance operational efficiency and drive sustainable practices. Our Energy Management solutions empower businesses to optimize their energy consumption, reduce costs, and minimize their environmental footprint.

In addition, our broad range of services encompasses everything from digital innovations to autonomous system operations, ensuring that your operations run smoothly and efficiently. With a strong focus on sustainability, we provide tailored decarbonization programs that help you meet regulatory requirements and achieve your environmental goals. Discover how we can support your journey towards a more sustainable and efficient future in the metal and mining sector.

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Products and solutions for the metals industry

How will the industry adapt to the changing world?

Our energy solutions for the metal industry

Powering the industry on both routes

Use cases

Explore the use cases in-depth:

Low/no-carbon power production

Energy management

Grid infrastructure

Electric arc furnaces (EAF) power compensation

Compression

Waste heat recovery system (WHRS)

Waste heat integration in carbon capture

Green hydrogen production

Hydrogen mixing skids

Mining is a key enabler for the clean energy transition

We support your journey:

A wide range of solutions and consulting services for the mining and metal industry

Click below to learn more about our full range of supporting services:

Services for industries

Power plant conversion solutions

Compressor modernizations and upgrades

Power transmission service solutions

Control systems

All services

Looking towards a sustainable energy future for your metal industry?